Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table of Contents
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Yanmar Diesel Engine
- 4 - Kubota Diesel Engine
- 5 - Hydraulic System
- Specifications
- General Information
- Operator's Manual
- Hydraulic Component Locations
- Relieving Hydraulic System Pressure
- Traction Circuit Component Failure
- Towing Traction Unit
- Hydraulic Hoses
- Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
- Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
- Hydraulic Schematic
- Hydraulic Flow Diagrams
- Special Tools
- Troubleshooting
- Testing
- Traction Circuit - Charge Pressure Test
- Traction Circuit - Relief Pressure Test
- Traction Circuit - Piston (traction) Pump Flow Test
- Traction Circuit - Front Wheel Motor Case Drain Leakage Test
- Traction Circuit - Reverse Reducing Valve (PR) Pressure Test
- Traction Circuit - Rear Relief Valve (RV) Pressure Test
- Cutting Unit Circuit - Pressure Test
- Cutting Unit Circuit - Relief Pressure Test
- Cutting Unit Circuit - Cutting Unit Motor Case Drain Leakage Test
- Steering/Lift Circuit - Steering Relief Pressure Test
- Steering/Lift Circuit - Steering Cylinder Test
- Steering/Lift Circuit - Lift Relief Pressure Test
- Cooling Fan Circuit - Pressure Test
- Cooling Fan Circuit - Fan Motor Case Drain Leakage Test
- Gear Pump Flow Test (pump sections P2 thru P5)
- Adjustments
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Priming Hydraulic Pumps
- Flush Hydraulic System
- Filtering Closed-Loop Traction Circuit
- Charge Hydraulic System
- Gear Pump
- Gear Pump Service
- Piston (Traction) Pump
- Piston (traction) Pump Service
- Rear Traction Manifold
- Rear Traction Manifold Service
- HI/LOW Range Manifold
- Front Wheel Motors
- Rear Axle Motor
- Front Wheel Motor and Rear Axle Motor Service
- Cutting Unit Motor
- Cutting Unit Motor Service
- Mow Control Manifold
- Mow Control Manifold Service
- Steering Control Valve
- Steering Control Valve Service
- Steering Cylinder
- Steering Cylinder Service
- Engine Cooling Fan Motor
- Engine Cooling Fan Motor Service
- Fan Control Manifold
- Fan Control Manifold Service
- Lift Manifold
- Lift Manifold Service
- Control Manifold Cartridge Valve Service
- Lift Junction Manifold
- Front Lift Cylinders
- Rear Lift Cylinders
- Lift Cylinder Service
- Hydraulic Reservoir
- Hydraulic Oil Cooler
- 6 - Electrical System
- General Information
- Electrical Drawings
- Special Tools
- InfoCenter Display
- Troubleshooting
- Electrical System Quick Checks
- Adjustments
- Component Testing
- Fusible Link Harness
- Fuses
- Toro Electronic Controllers (TEC)
- Ignition Switch
- Reel Enable/Disable Switch
- Engine Speed Switch (Yanmar Diesel Engine Only)
- Lower/Raise Joystick Switches
- Seat Switch
- Traction Neutral Switch
- Parking Brake Switch
- HI/LOW (Transport/Mow) Switch
- Cutting Unit Position Switch
- Backlap Switches
- Hydraulic Oil Temperature Sender
- Engine Temperature Sender (Kubota Diesel Engine Only)
- Relays with Four (4) Terminals
- Relays with Five (5) Terminals
- Hydraulic Solenoid Valve Coils
- Fuel Pump (Yanmar Diesel Engine Only)
- Fuel Pump (Kubota Diesel Engine Only)
- Fuel Stop Solenoid (Kubota Diesel Engines Only)
- CAN-bus Termination Resistor
- Diode Assembly
- Resistor Assembly
- Worklight Switch
- Service and Repairs
- 7 - Axles, Planetaries and Brakes
- 8 - Chassis
- 9 - DPA Cutting Units
- Table of Contents
- Specifications
- General Information
- Special Tools
- Gauge Bar Assembly
- Bedknife Screw Tool
- Handle Assembly
- Plastic Plug
- Cutting Unit Kickstand
- Spline Insert Tool
- Diameter/Circumference Measuring Tape
- Roller Rebuild Kit
- Turf Evaluator Tool
- Reel Bearing Installation Tool (cutting units with painted side plates)
- Cutting Reel Shim
- Cutting Performance Paper
- Pulley Alignment Tool
- Bedknife Top Angle Indicator and Mount
- Factors That Can Affect Cutting Performance
- Adjustments
- Service and Repairs
- Hydraulic Reel Motor
- Backlapping
- Bedbar Assembly
- Bedknife Replacement and Grinding
- Bedbar Adjuster Service
- Reel Assembly (cutting units with painted side plates)
- Reel Assembly Service (cutting units with painted side plates)
- Reel Assembly (cutting units with aluminum side plates)
- Reel Assembly Service (cutting units with aluminum side plates)
- Preparing Reel for Grinding
- Front Roller
- Rear Roller
- Roller Service
- Rear Roller Brush - Optional (cutting units with painted side plates)
- Rear Roller Brush - Optional (cutting units with aluminum side plates)
- 10 - Belt Driven Groomer (Optional)
- 11 - Universal Groomer (Optional)
- 12 - Foldout Drawings
- Electrical Drawing Designations
- Hydraulic Schematic
- Electrical Schematic - Traction Unit Model 03780 - Yanmar Engine (Serial numbers below 316000000)
- Electrical Schematic -- Traction UnitModel 03780 -- Yanmar Engine(Serial numbers 316000001 to 403350000)
- Electrical Schematic -- Traction UnitModel 03780 -- Yanmar Engine(Serial numbers above 403350001)
- Electrical Schematic - Traction Unit Model 03781 - Kubota Engine (Serial numbers below 316000000)
- Electrical Schematic -- Traction UnitModel 03781 -- Kubota Engine(Serial numbers 316000001 to 403350000)
- Electrical Schematic -- Traction UnitModel 03781 -- Kubota Engine(Serial numbers above 403350001)
- Electrical Schematic - Cab
- Main Wire Harness Drawing (Serial numbers below 316000000)
- Main Wire Harness Diagram (Serial numbers below 316000000)
- Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 316000001 to 403350000)
- Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 316000001 to 403350000)
- Main Wire Harness DrawingModel 03780 & 03781(Serial numbers 403350001 to 405699999)
- Main Wire Harness DiagramModel 03780 & 03781(Serial numbers 403350001 to 405699999)
- Main Wire Harness DrawingModel 03780 & 03781(Serial numbers above 405700000)
- Main Wire Harness DiagramModel 03780 & 03781(Serial numbers above 405700000)
- Engine Wire Harness Drawing - Yanmar
- Engine Wire Harness Diagram - Yanmar
- Engine Wire Harness Drawing - Kubota
- Engine Wire Harness Diagram - Kubota
- Seat and Console Wire Harness Drawing
- Seat and Wire Harness Diagram
- Power Center Wire Harness Drawing (Serial numbers below 403350000)
- Power Center Wire Harness Diagram (Serial numbers below 403350000)
- Power Center Wire Harness DrawingModel 03780 & 03781(Serial numbers above 403350001)
- Power Center Wire Harness DiagramModel 03780 & 03781(Serial numbers above 403350001)
Reelmaster 7000−D Hydraulic SystemPage 5 − 17
Mow Circuit
Hydraulic flow for the mow circuit is supplied by two (2)
sections of the gear pump (P2 and P3). Gear pump sec-
tion P2 supplies hydraulic flow to cutting units 1, 4 and
5 (front cutting units), while gear pump section P3
supplies cutting units 2 and 3 (rear cutting units).
A single mow control manifold is used to control flow
from the two (2) pump sections. The manifold includes
cartridge valves for control of each of the two (2) pump
circuits. Each mow circuit includes a solenoid controlled
proportional valve (SP1 and SP2), a logic cartridge (LC1
and LC2) and a circuit relief cartridge (RV1 and RV2).
All cutting reel motors are equipped with cross over relief
valves to prevent hydraulic component damage in case
a cutting reel should stall.
The Toro Electronic Controller (TEC) uses inputs from
various machine switches to determine when solenoid
proportional valve (SP1 and SP2) are to be energized.
The controller also provides a slight delay in activation
of the rear cutting units.
NOTE: The mow speed limiter must be in the LOW
speed (mow) position before the mow circuit can be en-
gaged.
Reels Engaged
When the reel enable/disable switch is turned ON with
the cutting units lowered, the proportional valves (SP1
and SP2) are energized by the TEC−5002 controller.
The energized valves shift to direct pump flow toward
the cutting unit motors. Flow from the valves is propor-
tional to current applied to the valve coil by the TEC. The
reel speed (defined by InfoCenter settings) provides the
input for the TEC to allow the appropriate current to the
proportional valve coils.
Flow through the proportional valves (SP1 and SP2) is
pressure compensated by the logic cartridge valves
(LC1 and LC2). The logic cartridge valve maintains a
pressure of 110 PSI (7.6 bar) across the proportional
valve. Any excess flow is returned to the oil cooler and
return filter.
Maximum mow circuit pressure is limited at each mow
manifold circuit by the relief valve (RV1 or RV2). The re-
lief valve pressure is 3000 PSI (207 bar).
When the reels are disengaged, the over−running iner-
tia load of the reels keeps driving the reel motors and
can turn them into pumps. The check valves (CV1 and
CV2) in the mow control manifold will open to keep the
reel motor circuit full of oil so the motors will not cavitate
(fill with air).
Reels Disengaged (Fig. 11)
When the reel enable/disable switch is OFF (or if the cut-
ting units are raised), the manifold proportional valves
(SP1 and SP2) are not energized, causing a pressure in-
crease that shifts the logic cartridges (LC1 and LC2).
The pump flow is routed through the shifted logic car-
tridge and out manifold port T1. Return oil from the man-
ifold is directed to the oil cooler and return filter.
Backlap
When either of the mow control manifold backlap valves
are rotated to the backlap (R) position, pump flow to the
cutting unit motors is reversed. This change in flow di-
rection reverses the rotation of the front or rear cutting
reel motors allowing the backlap operation.
Figure 11
1450 psi
1.6 CID
P1
G1
M3M4
T2 P2
G2
110 psi
3000 psi
.040
3000 psi
.040
110 psi
MV2MV1
SP1
M1
1450 psi
1.6 CID
1450 psi
1.6 CID
1450 psi
1.6 CID
1450 psi
1.6 CID
CV1
LC1
RV1
OR2OR1
REEL
#4 #1 #5 #2 #3
MOTORS
FRONT REAR
MOW CONTROL
M2
T1
RV2
SP2
LC2
CV2
MANIFOLD
Hydraulic
System